Wastegate: Testing and Inspection

Checking and Adjusting the Bypass Flap Control Boxes on the Turbocharger





Tools

Check and Adjust (Cylinder Bank 1 - 3)

Test

1. Raise the vehicle at the prescribed jacking points.







2. Fasten special tool dial gauge holder VW 387 onto the underneath of the camshaft housing (cylinder bank 1-3). Flanges with thread M 8 have been provided or this procedure.

3. Align tracer pin with push rod, set the dial gauge with pre-tension to 0.

4. Connect special tool pressure gauge 9103/2. Connect hand pump and pressure gauge together with branch pieces. Hang pressure gauge on stabilizer.

5. Remove vacuum hoses from the control box:
- Push a small screwdriver between connection nipple and vacuum hose.
- Widen vacuum hose a little and spray in e.g. silicone spray at the same time.
- Pull off vacuum hose.







6. Connect connecting piece (shop-made) and Tecalan line (shop-made) onto the control box and connect with the pressure gauge.

7. Produce overpressure of 0.5 bar with special tool tester 9160/1. Read off pressure on special tool pressure gauge 9103/2. Have a second person read off the stroke of the push rod on the dial gauge at the same time.

Prescribed stroke: 4 ± 0.5 mm.

Adjusting

1. Remove safety bracket.

2. Twist adjusting nut accordingly.
Turning "clockwise" - stroke smaller.
Turning "counter-clockwise" - stroke larger.

3. Fit safety bracket again.


Check and Adjust (Cylinder Bank 4 - 6)







1. Fasten special tool dial gauge holder VW 387 onto the underneath of the right camshaft housing.

2. Make tracer pin (shop-made). The tracer pin must be bent accordingly in the area of the deflector plate.

3. Carry out checking and adjusting, using the same method used on cylinder bank 1-3.